Method of making brushes



Nov. 27, 1951 .1. A. STARR METHOD OF MAKING BRUSHES 9 Sheets-Sheet 1 Filed Oct. 7, 1948 Nov. 27, 1951 J. A. STAR]? 2,576,546

METHOD OF MAKING BRUSHES Filed Oct. 7, 1948 9 Sheets-Sheet 2 INVENTOR. J0/721 H Sta/v" Nov. 27, 1951 Filed Oct 7, 1948 J. A. STARR METHOD OF MAKING BRUSHES 9 Sheets-Sheet 3 Nov. 27, 1951 J. A. STARR 2,576,546

METHOD OF MAKING BRUSHES Filed Oct. 7, 1948 9 Sheets-Sheet 5 Nov. 27, 1951 J. A. STARR METHOD OF MAKING BRUSHES 9 Sheets-Sheet 6 Filed Def. 7, 1948 R m E I J0/7/7 f2 Sta/v Fit Nov. 27, 1951 J. A. STARR METHOD OF MAKING BRUSHES 9 Sheets-Sheet '7- Filed Oct. '7, 1948 Nov. 27, 1951 .1. A. STARR 2,576,546

METHOD OF MAKING BRUSHES Filed 00f. 7, 1948 9 Sheets-Sheet a Nov.27, 1951 J. A. STARR 2,576,546

METHOD OF MAKING BRUSHES Filed OCt. '7, 1948 9 Sheets-Sheet 9 Patented Nov. 27, 1951 IHETHOD OF MAKING BRUSHES John A. Starr, Riverdale, N. Y., assignor to M. W.

Jenkins Sons, Inc., Cedar Grove, N. J., a. corporation of New Jersey Application October 'z, 1948, Serial No. 53,340

Claims.

This invention relates to a method of making tufted brushes having bristles of plastic material. The bristles may be made from any suitable plastic which is solid and hard at temperatures under 250 F., but which will soften and liquify when sufficient heat is applied thereto and will again harden and solidify when cooled. Experience has shown that brushes having bristles made from nylon filaments are very serviceable and are particularly adapted for certain uses.

In making brushes according to my improved method, I first form individual plastic bristle tufts comprising a plurality of bristles extending upwardly from a thin hard solid base which is integral with the bristles. slightly greater area than the area of the bristles at their junction with the base so that I have in effect an annular bead about the base of the bristles. In making the individual tufts I combine a multiplicity of endless plastic filaments of the desired diameter into a rope of filaments. From the rope of filaments I successively cut sections of predetermined length. I then subject one end of each of these sections to sufiicient heat to fuse the ends of the bristles together to form the thin solid beaded base integral with the bristles. Then I apply rubber cement to the base and lower ends of the bristles after which I insert the lower ends of the. tufts into spaced apertures through a narrow endless strip of uncured rubber with the beaded base of the tufts embedded in the rubberstrip and the bottom thereof flush with the undersideof the strip. Next I apply a thin coat of cement to the underside of the strip and to the base of the tufts after which I pass the rubber strip with the tufts secured thereto through a heating and drying chamber wherein the rubber cement is dried until it is no longer tacky. The rubber strip is then tightly wound upon a suitable core with the edges of adjacent convolution in con tact. The core with the uncured rubber strip wound upon it is then subjected to sufficient heat to cure it and cause it to form a hard homogeneous sheet about the core.

The principal object of my invention is to provide a method of making tufted brushes, having plastic bristles, which will speed up the manufacture of brushes of this type and thereby materially reduce the cost thereof.

Another object of my invention is to provide a method of making tuftedbrushes which will produce brushes superior to those made by other known methods.

The base is of if 2 tion will be apparent from the following specification and the accompanying drawings forming a part thereof wherein:

Fig. 1 is a side elevation of an individual tuft such as is used in making brushes according to my improved method;

Fig. 2 is a view similar to Fig. 1 showing a film of rubber cement applied to the base and lower end thereof;

Fig. 3 is a sectional side elevation showing a secured thereto helically wound upon a core after it has been passed through a drying chamber wherein the rubber cement was dried;

1 Other and more limitedobjectsof the inven Fig. 5 is a fragmentary vertical sectional View through a completed brush showing the rubber strip and the rubber cement cured into a solid hard homogeneous sheet upon the core;

Fig. 6 is a top plan view of a machine especially adapted for automatically forming individual bristle tufts, and inserting them in spaced apertures through an endless narrow strip of uncured rubber according to my improved method;

Fig. 7 is a central vertical section taken on the linel-I of Fig. 6;

Fig. 8 is a horizontal section taken on the line 88 of Fig. '7; TV

Fig. 9 is a horizontal section taken on the line 99 of Fig. 7, and showing in plan the driving mechanism by which the various elements of the machine are operated in timed relation to each other;

Fig. 10 is a vertical section taken substantial- 1y on the line l0-I0 of Fig. 9;

Fig. 11 is a vertical section taken on the line H--|I of Fig. 9;

Fig. 12 is a vertical section taken on the line l2-l2 of Fig. 9;

Fig. 13 is a detail view of one of the operating cams;

Fig. 14 is a detail view of another operating cam;

Fig. 15 is a fragmentary section taken on the line l5-|5 of Fig. 8;

Fig. 16 is a vertical section taken substantially on the line l6l6 of Fig. 8;

Fig. 17 is an enlarged vertical section through the rotating punch by which the holes are cut through the rubber strip; and Y Figs. 18, 19 and 20 are diagrammatic views illustrating the operation of the machine.

Referring now to the drawings by reference characters, the letter A indicates an individual tuft of plastic bristles which at one end thereof have been fused together to form a hard solid base B integral with the bristles and having an annular bead C therearound. After the tufts- A are formed a thin layer D of rubber cement is applied to the base B and around the lowei end of the tuft by immersing the lower end of the tuft in a cement bath. The cemented ends of the tufts are then inserted in apertures d through an endless narrow'strip' m ofui'icured' rubber. The beaded base B is embedded in the strip l5l with the bottomxofthebase;

with the underside of the strip l50. After tufts is moved downwardly to insert the projecting cemented end of the tuft into a registering hole iii' the-rubberstripJ As the holder is retracted,

thetuft; held by the rubber strip is completeiywitndrawn from the holder. The foreigoing operation's; are successively repeated with A have been inserted in the aperturesdfiil-a' thin layer E of rubber cement is applied to the underside of the strip andrtethe botteins-o the bass B. The Strip i I50 with the tuft-s A secured thereto is then-passed through adry ing chamber 238 (Fig. 6) wherein the rubber cement is dried until itis no'longe'rtacky. 'After passing through the drying chamber fiefithe strip 151 is tightly wound upon a-core F withthe edges of adjacent convolutions contacting each other as is shown in Fig. 4. The core E'withthe strip 151 wound thereon is'then placed-in a-suitabIechamber' where sufiicient heat is applied theret'o'to cure and harden the rubber strip. As therubberstrip is curing the convolutien's thereof "on the core F all fuse together and forma nardhemogeneous sheet G with the base endof the tufts A firmly embedded and held therein as hewn in Fig; 5.

In Figs.r6 to 20, inclusive, 1- have illustrated a machine for automatically forming individual bristle tufts, such as shown in Fig. 1', applying i cement to the lower ends thereof and-inserting them in apertures through an endless narrow strip of uncured rubber, all-in accordance with each holder as the holders are, respectively, intermittently moved to successive stations by the turret.

Referring now to Figs; 6 to 20, inclusive, by reference characters"; the numeral l i'rldicates atable top which is supported by suitable 1e s,-n ot shownr' A'gear careers secured-mineupper side of' thetable topl'by -boltsd; seeuratotne-ten of the gear case 2-b'y bolts 4 atone side thereof is an upwardly extending bracket 5 which has upper and lower bosses Band 1, respectively,-

, formed integral therewith An am an secured 1 to the top of thebracket eabout theupper end my improved method of making tufted brushes. N

This machine per se forms no part of this'application but is the subject-matter of my co-pendiiig' application Serial No. 53,339, filed- (ectober '7, 1948.

In making bristle tuftswith this machine I first-'combinea plurality oflcng plastic filaments intoa-rope, one end of which is inserted; into the feeding mechanism of the machine.- The machine comprises generally a rope feeding mechanism, aturret having four; holders thereon and 'fourstations past which the holders are successively advanced by the turret with an intermittent movement. Thevmachine also includes means for'punching and advancing a long strip of uncured rubber in timed relation with the operation of the rest of the machine. At the first station a predetermined length'of the filament rope 'is inserted into each' holderan'd cut off as the holders are successively brought into register with the rope feeding mechanism. The holders are then advanced to the second's'ta'tion with the severed sections of the rope therein. Here the rope section is forced downwardl'y'in the holder until about of an inch thereof projects from the bottom thereof, after which the holder is moved downwardly untilthe projecting end of the rope is brought into engagement with a heating element which softens and fuses the ends of all the filaments together. The holder is then advanced to the third station, during wh'ichtime the fused-ends of 'tnenmmentsceei and solidify into a thin hard shet 'i n'tegral ti ithof the boss 6 and extends outwardly therefrom; The freeen'd of the arm 8 has-'averticalbore 9 therethrou'gh in which the upper end 0f a-ildh' rotatable reciprocal rod lfl is s1idab1ymounted.

The lower end'of the ro'd la is slidably'rnounted in and extends thrOllgh a cylindrical sleeve l l' Which'i's rotatably m01lrit'edin bearin s [E E-lid" l3 which are suitably secured'to the top and bottom, respectively, Ofth-tabletop l in aXial aima meht With the bore 9-. V The rod I0" is intermittently' reciprocated, witha dwell at'the'end of its movement} in" each-direction, by anoscillatory arm [4 which is pivotally connected at-l5- to bracket I6 which issecured to and extends downwardiy from the underside-of the table to and the sleeve'lI-is intermittently rotated, in timed relation, to the reciprocation of the rod I0, by a ratchet andpawl mechanism generally indicated The bosses 6 and Thave axially aliiied vertical bores l8 and i9, res ectively; therethrollgh in which is mounted-the rope feediilgmechanism generally indicated by the numerarzn. A cutting mechanism-generally indicated by the numeral 2| is mou'nt'ed on the gear case 3 and operative to successively cut sections'of predeter mined length frbm'thje rope bffilamehts as'th'e rope is intermitteritlyfed downwardly in 'p'red termined lengths by'tlie rope'feedi'ng mechanism.

The strip feeding and punching mecha'nism timed relationto each other from a shaft 'zswnmn is rotatably supported *by brackets 24 and-25 which aresecured to "and extend downwardly from theundersid'e offth'e table top l-. V The shaft 23 is' 0'0 nStant1y rotated diirihg operation byany' suitable source or power (not-shown) through a drive chain 26 andasp ocketzi which i rigidly secured to the shaft 23; The arm l4, through which the'rod Ill is reciproeated, is oscillated. by a cam 28 which is'pi-nned or'oth'erwise secured to the shaft 23; and the ratchet and pawl'mechar-T IT, through-which the sleeve 'l'| iS -iflter-.

inittently rotated through 90 at a time, is driven by a cam 29 secured to the shaft 23 adjacent the cam 28. The rope feeding mechanism 28 is operated by the rod l8 through an arm 38, which is rigidly secured at one end thereof, to a part of the rope feeding mechanism, as indicated at 3|. Near the other end of the arm 38 is an aperture 32 through which the rod l8 extends, and in which the rod I8 is freely slidable. The strip feeding and punching mechanism is operated from a short shaft 33 which is rotatably supported by brackets 34 secured to and extending downwardly from the underside of the table top and the shaft 33 is constantly rotated by the shaft 23 through a drive chain 35 and sprockets 36 and 31 secured to the shafts 23 and 33, respectively. The cutting mechanism 2| i operated from a short vertical shaft 38 which is rotatably supported in a bearing 39 in the gear case 2. The shaft-38 is driven through bevel gears 48 and 4| from a short horizontal shaft 42 which is rotatably supported by a bracket 43 secured to and extending upwardly from the table top and the shaft 42 i constantly driven from the shaft 23 through a drive chain 44 and sprockets 45 and 46 secured to the shafts 23 and 42, respectively.

Secured to the lower end of the rod ID by a pin 48 is an extension generally indicated by the numeral 49. This extension comprises a base 58 and a pair of spaced arm 5| extending downwardly therefrom. The base 58 has a vertical cylindrical recess 52 therein into which the lower end'of the rod l8 fits. A roller 53 is rotatably supported between the arms 5| near the lower end thereof by a pin 54 which is secured to and extends between the arms 5|. The free end of the arm M is reduced as indicated at 55 and extends between the arms 5| above the roller 53 and under the base 58. Then, as the arm I4 is oscillated between the position shown by full lines and the position shown by dot and dash lines shown in Fig. 10, the rod I8 will be reciprocated between the position-shown by full lines and the position shown by dot and dash lines. The arm I4 is moved from the full line position to the dot and dash line position in Fig. by the cam 28 engaging a roller 56 which is rotatably mounted upon a stud 51 secured to the arm I4; and is moved back from the dot and dash line position to the full line position by the cam 28 engaging a roller 58 which is rotatably mounted upon a stud 59 carried by an arm 68 which is secured, as shown, to the arm |4. By reference to Figs. 10 and 13 it will be seen that the shape of the cam 28 is such that it will cause a dwell in the movement of the arm l4 and consequently the rod I8, at both the upper and lower limits of their movement. The ratchet and pawl mechanism'll, shown in detail in Figs. 9, '10 and 11, which intermittently rotates the sleeve comprises a pawl 6| and a four-toothed ratchet 62. The ratchet 62 is secured to the sleeve directly below the bearing |3 by a set screw 63, and the pawl 6| is pivotally secured at 64 to the outer end of an arm 65 which is rotatably mounted upon the sleeve between the ratchet 62 and a collar 66 which is secured to the lower end of the sleeve b a set screw 61. The pawl 6| is resiliently held in engagement with the ratchet 62 by any suitable means. One end of a link 68 is pivotally connected to the arm 65 as indicated at 69, and the other end thereof is pivotally connected to a slide I8, as indicated at The slide 18 is repiprocated bytheca'm 29 which engages rollers" niounted onstfid's 'I4'carried by the'slide' HI; The

6 slide 18 extends through aslot 15 in a bracket 16 which is secured to and extends downwardly from the underside of the table top and the slide 18 has an elongated slot 11 therethrough through which the shaft 23 extends. This arrangement accurately guides the slide 18 as it is reciprocated by the cam 29. From this it will be seen that,

as the slide 18 is reciprocated, the arm 65 will be oscillated about the sleeve H as a pivot; and that through the pawl 6| and the ratchet 62; the sleeve I will be intermittently rotated. The arrangement and proportions of the parts are such that for each movement of the slide 18 in one direction, the sleeve II will be indexed through 90", and during the movement of the slide 18 in the opposite direction, the sleeve U will remain stationary. The mechanism for reciprocating the rod l8 and the indexing mechanism for the sleeve II are so timed with respect to each other that the rod ID will be reciprocated during each swell of the sleeve I.

, A turret disc 88, having flanged collars 8| and 82, secured to opposite sides thereof is rigidly secured to the sleeve II by a set screw 83, with the collar 8| seating on the upper end of the bearing l2. The set screw 53, by which the ratchet 82 is secured to the sleeve l and the set screw 83, by which the disc 88 is secured to the sleeve cooperate with each other to hold the sleeve against vertical movement. The disc 88 has four holders 84mounted therein. These holders are all equidistant from the axis of the sleeve II and are spaced 90 from each other.

Each holder 84 comprises a bushing 85, a reciprocal sleeve 86 and a spring 81. The bush ings85 are secured in apertures in the disc 88 and the sleeves 86 are slidably mounted in the bushings 85. Each sleeve 86' has an enlarged conical head 88 formed on the lower end thereof and a collar 89 removably secured to the upper end thereof. ,The springs 81, which are disposed about the sleeves 86 between the collars 89 and flanges 98 on the bushings 85, normally hold the sleeves 86 in their uppermost position, but will allow them to be moved downwardly as will be hereinafter described.

A plate 9| having a flanged collar 92 secured thereto is slidably mounted upon the upper end of the sleeve The plate 9| is adapted to be moved up and down upon the sleeve H, but is held against rotation by a rod 93 which is rigidly secured in a bore 94 in the boss 1 and extends through abushing 95 carried by the-plate 9|. A spring 96, which is disposed aboutthe sleeve between the disc 88 and plate 9| normally holds the plate 9| in its uppermost position which is determined by the bushing 95 engaging the boss 7, The plate 9| has three bushings 91, 98 and 99 mounted thereon which extend through apertures I08 in the disc 9|. The bushings 91, 98 and 99 are all equidistant from the axis of the sleeve H with the bushing 9'! disposed to one side of the bushing 98 and the bushing 99 disposed 90 to the other side of the bushing 98. The axis of the rope feeding mechanism 28 is disposed midway between the bushings 9i and 99 diametrically opposite the bush ing 99, as is clearly shown in Fig. 2.

A plate |8|, having a flanged collar I82 secured thereto, is pinned to the 'rod |8between the arms Band 38 as indicated at I03. The plate |8| carries three ejector rods |84, I85 and I86 which are adjustablyheld in apertures I81 in the plate |8| by set screws I88; The rods I84, I85 and I86 extend downwardl'yfrom the plate" |8 and intdthe' bushings 91, 98'and 99," respectively."

"lihezirope feedingimechanism itncomprises a piecewof :steel '='tubin,g- :I to; which is. vslida'bly mountediin the bore -=I8 inthe bossffi. :Remov ablyjsecuredwin,thetubingi-HI] is a sleeve II I I of case-:hardened2steel. fThersleeve II I extends a shprtdistanceout of the-lower end oi theitubing IeLIl-andhasithe-armf30 secured thereto byithe bolt 3I. A thin Walled tube I12 of'stainless chrome :steel is secured in :the lower end .of the sleeve IqI-I :and-zextendsdownwardly therefrom in- .to the z'uppenend; of sa bronze bushingv I I:3-'which iSrIIlOllIllifid' in thebore tom the boss I. The lower endbof the tubeaIIZzha-s asnonical taper IM formed thereon. A; tool :steel splug -I I5 :having .:a conical aperture -I I 6 (complementary to ;the taper @qlS-SG'GLIIEd in:the:lower end:oi the bore I9s.beneathfbushine ,11 I 3. Asfthe'tubing I I I] is: reciprocat'ed, :aswill: be lh'ereinafter' described, :the tapered :end I'M-of thetube I12 will5seatlnthe conical aperture 146 when the :tube is at the lower end ofits movement. :An arm 'IzITI :Which is irigidlyssecured to =the=upper end or the tubing I-I'O has a pair :of spacedabrackets :I IE8? mounted thereon between-which isrrotatablyrisupported a groovedtpulley I I.-9. .A second pulley l2fli4is rotatably'wsupported between :spaced brackets 'I2I securedktdthe bracketzb. The numeral I22'indi'cates a reelaupon whichath'en'ope I 23 of' plastic filaments 'wound :andifrom which tthe rope is withdrawn .during operation. The xrope of. 'filamerits I 23Iisafed ifromithe .reelf I 22, ethence :under the pulley lizfliand sthenxnppver the ":pulley II I8 and-:dowmthrough the sleeve I I I :andtube M2 'to the end I1I42of1the tube.;I.I2.. Most -:plastic .filaments capable :of ."beingiused. in forming bristle tufts'havesa iveryabrasive effect. upon :the sleeve III .andithe ZtubeiILIZ. With .the construction 'shownithese parts vcanu'beureadily replacedafter theyabecome lwornl .The putting-mechanism 2| comprises a blade l25ihavingraadiagonal beveled putting-edge I26. The bladesllti isiremovably secured to a reciprocal slide -I21, by bolts "H28, which is =sli'dalo'ly mounteddn za slot129 formed-inthe top of the gear: case 2 lheslide I'Z 'I' has an elongated" slot I 30 therethrough through which-the shafttfi extends,=-and it is reciprocated'by a'cam I3I which is F-secured to I the upper end of ithe shaft 38 and, as it is rotated, engages *rollers I-32'-rotatably mountedon studs I33 carried by the slide I21;

The blade I 25 enga'ges the" lowerend of the plug I-'I5*and-as it isreciprocatedfthe cutting edge H 5 oi-the blade cooperates with the plug to shear ofi'sections from the rope I 23-'-which have beenprojectedout through the aperture II6 by the rope feedingmechanism 2-0.

=-As previouslystated, -all orthe var-ious mechanisms whichhave beendescribed indetail are operated in timed relati'on'toeach other from the shaft 23 which is constantlyrotatedduring operation. Asthe-rod Iflis moved'downwardly by" the armI' I' it carries the plate IOI'down with it which in=turn moves the-ejector'rods I"II4,'IB5 and I06 down through the bushings 91, 98 and '99, respectively-as is shownini igs. l8, l9fand "After the rod"l il-has' beenmoved downwardlya'short distance, the plate I0 I engages the arm 30 after whioh'the'plate I'BI'an'd'arm-"30 -move downwardly'together. 'ASZthe arm 30 is moved downwardly it' in .turn pulls the tubing I I0 and all ofthe parts. carriedthereby downwardly until at the" lower'limito'f movement of 'the rod I0,

the conical; end IILOfLtheLtubeIIZ seatsin the. conical aperture I I'Blin th'eplug, H5. Upon a mi eeeiers jiemeiwer 9'? it. #9 1 after the plate IOI -engages the. arm .30. acupshaped member I-35,:rigidly seouredto the rodv II, will engage the top-of the collar-92 secured to the plate 91, after which the plates .9l and IOI and the arm will ;all move downwardlytogather. As the plate 9I is moved-downwardly about the sleeve II by the cup-shaped member I ;the member I35 will telescope the upperend of the sleeve I I. As the plate9l is moveddown- Wardly, the lower ends of the-.bushings--98,-99 and 91 will-successively engage the upper ends-of the sleeves 86 .of the holders vIl l thereunder and .upon further movement of the plate IN, the bushings 97,98 and 99 will depress the sleeves=86-of the holders 84. in thebushings thereof-.against-the pressureof-thesprings- 81, which will returnthe sleeves 86 to their initial position as the;plate .9I moves-back to its initial position.

As therod Ill ismoved upwardly by the -cam 28 and arm l4, it will carry the plate IIII and'the ejector rods I55, Iflfi-and'lflfi up with it and the spring 96 will return'the plate BI and bushings 97, 98 and .98 thereon back to their initialpositions. :Aspring I36, which surrounds the-rod I0 between the plate 9| and the arm-30, is provided to return the rope feeding mechanism 20 to .its initial position.

The .up and down travel of the-rod I0 isalways constant and cannot .beohanged or adjusted. Consequently, in order to adapt the apparatus for'fol'ming different lengths of tufts, meansare provided by which the length .of the stroke of the rope feeding mechanism can be varied as the length of the stroke of the rope .feeding mechanism determines the :amount of rope. fed during-each cycle, and this in turn determines the length of'the tuft. Means are alsoprovided by which .theinitial position of theejector-rods I84, I and I06 can be changed-inaccordance withwany change in the stroke of the-rope feeding mechanism. In order to adjust the stroke of the feeding mechanism 20; it-isonly necessary to adjust the initial position thereof,.as therope feeding mechanism willnot start to move downwardly until the plate IIiI engages thearm 30. This adjustment is accomplished by means of a stop "I31 which is. adjustably secured to the upper end of arod .93 by a set screw I38. 'In order to change theinitial .positionof the ejector rods JIM, I 05 and I96. it isonly necessaryto loosen the set screws I 08 and move the rods to the desiredposition, after which the screws I08 are again tightened.

. As previouslystatedthe.cam'ZB is so shaped as toproduce a dwell in the movement'io'ftheirod Iii) at both the upper andlower limits ofits movemerit, which in turn will'produ'ce like "dwells in the various'mechanisms operated by therod III. As the rope .jfeedihgtmedhanism moves downwardly, .it projects .apredtermined length of ropelout throughftheaperture IIB andinto'a holder "84 therebelow. "'Then', during the dwell at the? lower limit of its movement, the 4 cutting blade I'2'5'is moved: towards the'projecting sectionof'ropeuntilthe'-cutting edge I 26 just-engages-the rope. .The bladeIZS then *dwellsholding the rope "stationary, while the rope feeding mechanism .TBtUIIlS to its initial position, after whichfthe "blade I25'is moved 'on "farther to shear the ,projectingsection I'4Ilf10mthe vrope; leaving 'it in 'the holderMwith the en'djHII thereof, projecting .a' [short distance abovejthe a e iem drawn from the reel I22,"and the next section I40 is left extendin from the end of the tube II2 into the bushing H3 in readiness to be projected out through the aperture H6 and into the next holder 84.

All of the above described operations occur during the dwell in the movement of the turret disc 80. After the rod I has been returned to its uppermost position and all of the mechanisms operated thereby have returned to their initial positions, the-ratchet and pawl mechanism I1 indexes the turret disc 80 through 90, after which it dwells while the rod I0 and various mechanisms connected thereto are again operated.

As the turret disc is indexed around it advances the holders 84 successively past four stations A, B, C and D at which stations the holders dwell as the various mechanisms described are operated. At station A, section I40 of predetermined length is projected from the rope feeding mechanism and into a holder 84 therebelow, after which the section is sheared off leaving the upper end I4I thereof extending a short distance above the holder, as has been described. AS.

each holder 84 moves from station A to station B, the projecting end I4I of the rope section I40 isengaged by a spring arm I42 which depresses the section I40 within the holder until the upper end thereof is flush with the top of the holder. The spring arm I42 is secured to one side of the boss I as indicated at I43 in Figs. 8 and 15.

At station E, the ejector rod I04 first forces the section I 40 downwardly in the sleeve 86 of the holder 84 until the lower end of the section extends out of the sleeve a very short distance, about 'g gnd to 1 6th of an inch. The sleeve 86 is then moved downwardly from the position shown in Fig. 19 to the position shown in Fig. 20 by the bushing 91 until the projecting end of the section is brought into engagement with a suitable heating element I45 as indicated at I46. The heating element I45 heats and softens the ends of the filaments causing them to all fuse together. From station B, the holders 84 are advanced to station C. While the holders are advancing from station B to station 0, the fused ends of the section of filaments'cools and hardens into a thin solid base B integral with the filaments and slightly greater in diameter than the diameter of the section I 40, thus forming the bead C around the lower end of the section.

At station 0, the ejector rod I forces the lower ends of the sections I40 from the sleeves 86 still further, as indicated at I41, and then the bushing 98 depresses the sleeve 86 from the position shown in Fig. 19 to the position shown in Fig. 20 until the projecting end of the section is immersed in rubber cement I48 in a pan I49, to apply a thin film of cement to the immersed end of the section.

From station C, the holders 84 are advanced to station D where the cemented ends I41 of the sections I40 are successively inserted in apertures I50 in a relatively narrow thin endless strip I5I of uncured rubber, which is advanced to station I) in timed relation to the advancement of the holders 84 thereto. The insertion of the ends I41 into the apertures I50 is accomplished by the downward movement of the sleeves 86from the position shown in Fig. 19 to the position shown in Fig. 20. The wet cement on the ends I41 acts asv lubricant and facilitates the insertion of the ends into the, apertures I50- The ejector 19 and 20.

' rod I06 merely acts as a stop to prevent the section I40 being forced back into the sleeve86 as the end I41 is being forced into the aperture I50.

The operation of the apparatus as just-described is shown diagrammatically in Figs.;l-8, In Fig. 18 the various mechanisms are shown in their initial positions with the end of the rope I23 flush with the bottom of the plug I I5 ready tobe projected out through the aperture II6-into the holder 84 therebelow. In Fig. 19 the various mechanisms are shown in the positions they assume just as the cup-shapedmember I35 engages the collar 92 on the plate 9| preparatory to moving the plate 9| downwardly. In this position, the end section I40 of the rope I23 has been only partially inserted in a holder 84; and the ejector rods I04, I05 and I06 have been moved downwardly until they extend out below the bottoms of the bushings 91, 98 and 99, respectively. In Fig. 20 the various mechanisms are shown at the lower limits of their movement. From the psition shown in Fig. 20 thevarious mechanisms move back to their initial positions as shown in Fig. 18 which completes the cycle of operation. 7

After the rubber strip I 5| leaves station D with the sections I40 secured in the apertures I50,it passes over a roller I 52 which takes cement from the pan I49 and applies it to the bottom of the strip. After leaving the roller I52, the strip I5I passes through a drying chamber 230 where the cement is dried. After leaving the drying chamber the strip I5I, with the sections I40 securely cemented in the apertures I50, may be immediately wound upon'a core or mandrel to form a brush or it may be coiled and stored for future use. j

The mechanism 22 for cutting the apertures I50 in the strip I5I and feeding the strip past station D in timed relation to the operation of the rest of the apparatus will now be described. The mechanism is all operated by the shaft 33 which is constantly rotated during operation'by the main shaft 23 through the drive chain 35 and the sprockets 36 and 31 as previously described. The punching mechanism is mounted upon a standard I60 which extends upwardly from a base I6I which is adjustably secured to the top of the table I by clamps I62 and bolts I63. A punch holder I64 is reciprocally-and rotatably mounted in alined bearings I65 and I66 in spaced bosses I 61 and I 68 integral with the standard I60. A sprocket I69 is slidably keyed upon the punch holder I64 between the bosses I61 and I68 as indicated at I10. The punch holder I64 is constantly rotated at high speed during operation from a vertical shaft "I by a sprocket I12 secured to the upper end of the shaft I1I, a drive chain I13 and the sprocket I69. The vertical shaft "I which extends down through'the table top I is rotatably supported by a suitable bearing bracket I14 secured to the underside of the table top I. Secured to the lower end of the vertical shaft I1I is a bevel gear I15 which meshes with a bevel gear I16 secured to one end of a horizontal shaft I11, rotatably supported in a suitable bearing bracket I18 secured to and extending down from the underside of thetable top I. A pulley I19, which is driven from any suitable source of power by a belt I80, is secured to the other end of the horizontal shaft I11. The shaft I1I is thus driven by the belt I through the pulley I19, shaft I11 and bevel gears I16 and I15.

Secured to the upper end of the punch holder '464 is a wheel I 8 I having an annular groove 182 therein. A pair of diametrically-opposite pins 183 whichare carriedhy a yoke I 84 extend into *the groove I82. The yoke I84 isseeured-"toone end :of a rocker arm 1 85 which is rotatably" --mounted-on-a shaft I86 between spaced arms '18! integral with thestandard i 50. The-other-end- -of .:the rocker 'arm 185-is pivotally connected at I88 "to .:the upper end of-a-connecting rod 189. The lowerend of theconnecting rod 189 is connected "-to anadiustable crank 196 secured to one end I of the shaft '33. From this it-will be seen that "as --the =shaft 33 rotates, the rocker arm we will 'be oscillated on the shaft 185.

The rocker arm as it is oscillated will impart a reciprocal-movement to the punch holder 1B4 through-theyoke =l-8 4,pins I83 and wheel l8l.

A cuttin punch NH is removably "secured-in amecessiSZ in the lower end-of thepunch holder "H55 by a set screw 1 93. The punch 191 comprises a thin walled tube I94 of hardened steel-the lower end of which has been diagonally cut as indicated-at I95. The outer wall of thetube is bevelled -as indicatedat I96 to provide a sharp cutting edge !91. A plunger I98 -is slid-ably mounted in the lower end of the tube 1-94 and the upper end of the tube is closed by an apertured screw plug I-99. A-rod 'ZlEfl-having an enlarged head 20-! is inserted through the 'aper- =ture =in the plug 199 and screwed into the =upper -end of the plunger-as indicated at 202. -A spring 203 disposed within the tube 194 about themed 2053 between the screw plug 1-99 and the inner end of the plunger [98 normally urges the --plunger' I98 outwardly and the head-201 limits the outward movement thereof.

uncured rubber strip and prevent anydisplacement thereof as it is pushed forwardly by the rollers 205 and E. It is during the dwell in the movement .of the strip .15! that the punch 1-9] is reciprocated to cut the apertures ISELJIt is also duringqthis dwell "that a .section HID .of

rope filament is inserted in a previously cut aperture. A hardened plug 268 "having a bore 2-08 in alinement with'the punch l9! cooperates with the punch lB-l in cuttingthe apertureiill.

The roller 285 is secured to the. upper end of..a shaft 21-10 which is rotatably supported in suitable bearin s 2H and 212 secured to the table J on Opposite sides thereof. 'The'rollerxzofi is secured to the upper end of ,a shaft 2 [*3 which is rotatably mounted in suitable supports .secured to the tabletop l. fIhe shaft .218 is intermittently'rotated in a clockiwse direction (Figs. 8 and 9) by a pawl2l4 and a ratchetiZ-Ii, which in turn are operated by the .shaft '33 through suitable linkage. The shaft 213 is rotated in an anticlockwise direction by a gear 21-6 which is secured to the shaft 210 and-meshes with a complementary gear (not shown) secured to the lower end of the shaft 2L3. The gear 2l6 is pinned to the shaft 2H] directlybelowthe bearings 212 and the ratchet 215 is se cured te t-he shaft 210 directly &belowi=.theegear ""246. The pawl i244 ispivotally secured,. -as:in- "'dicated -'at 2 'l 1,-- to 1 the outer end .of :an arm 218 which is rotatably mounted on :the :shaft [0 below the ratchet H5. The pawl 2154 is :resi-liently held iniengagement -with the ratchet by -any=suitable means One end of..aflink 12119.15 -pivotally" connected to the arm 24-8 :at .220, and 'one end-of a link 221 is connected toan adjustable crank mechanism 222 secured torone end-of the shaft. 33. Hhe adjustable crank --mechanisms 1'90 and 22-2 are identi'calzand of standard well known construction. Consequently it is-not believed*necessary to describe them in detail herein. The link 2l9 and 2%| are connected together by a "universal J coupling 223. From the foregding it-W-ill be apparent that =as-- the shaft 33 *rotates thearm z t-'8 will the oscil1a'ted "which will "impart-an intermittent retary -movement to the shaft 210 through "the -=pawl "-2 M and ratchet "2-1 5; "and that the same intermittent movement in -the-opposite--=direc- 'tion will' be imparted to-t-he' shaft 213; through the gear 2I6 on the shaft 2H1 and the comple- *mentary-g'ear onthe shaft 2-13.

.As previously "stated, the "strip feeding and punch'ing mechanism is operaJtedin-timed re- 'lationto the operation Ofjthfi" rest of'the apparatus. The strip 151 is "advancedat the same time the turret disc $80 is indexed which is: during Ithe'dwell of'the variouso'ther mechanismtin their "initial positions; and'the punch "I 9'] :is re- ,ciprocated ,tocut the apertures J50 during .the ,reciprecation .of the .rod ill! "and the operation of the various mechanisms .c'onnected thereto.

"From the foregoing it will beapparent to 'those skilled in this art that 'Ilhave provided a very ,Simple. and effective method for accomplishing the Qbiectsof my invention.

vIti obvious that the method may he carried -nut by other .apparatus than that shown and described herein,..as other-ways and means will occ-ur to. those skilled in thwart, and the invention imay bezotherwise variously embodied within the scope 0f the [appended claims.

Whatis .claimed is 1. The method- 0f making .brushes comprising forming individual tuft -bf plastic bristles having the corresponding ends ,of said bristles fused into a thin solid sheet integral with said bristles, securing the fused ends .of said tufts in spaced apertures in-a narrow endless strip .of uncured rubber, winding said strip upon a core with the edges of adjacent .convolutions in contact with ,each .other, and then applying sufficient heat thereto .to .cure saidstrip and cause ;it to fuse into a homogeneous .sheet upon :said core.

2; Themethod of making brushescomprising forming individual tufts of plastic-bristles having .the corresponding .ends of said bristles fused into a thin solid sheet integral withsaid'bristles, ,aipplying cement .to the fused endsof said tufts, inserting the .cementedends of .said tufts ,in alined apertures in a .narrow endless strip .of uncured rubber. windingsaid strip upon -.-a core with the edges of adjacent .convolutionsin .contact with each other, and then applying-sum,- cient heat thereto to cure said strip. and cause it to fuse into a homogeneous sheet upon .said

core.

The m th d of making brushes comprisin forming individual tufts of plastie bristles having the correspondingends of said bristles fused mtb a thin solid sheet integral with said bristles, securing the fused ends of said. tufts in spaced apertures in a narrow endless strip of uncured rubber, applying cement to the underside of said strip, winding said strip upon a core with the cemented underside of said strip engaging said core and the edges of adjacent convolutions engaging each other, and then applying sufficient heat thereto to cure. said strip and cause it to fuse into a homogeneous sheet upon said core.

4. The method of making brushes comprising forming individual tufts of plastic bristles having the corresponding ends of said bristles fused into a thin solid sheet integral with said bristles, applying cement to the fused ends of said tufts, inserting the cemented ends of said tufts in alined apertures in a narrow endless strip of uncured rubber, applying cement to the underside of said strip, winding said strip upon a core with the cemented underside of said strip engaging said core and the edges of adjacent convolutions en-' gaging each other, and then applying sufficient heat thereto to cure said strip and cause it to fuse into a homogeneous sheet upon said core.

5. The method of making brushes comprising forming individual tufts of plastic bristles having the corresponding ends of said bristles fused into a thin solid sheet integral with said bristles, applying cement to the fused ends of said tufts, inserting the cemented ends of said tufts in alined apertures in a narrow endless strip of uncured rubber, applying cement to the underside of said strip, subjecting said strip to only sufficient heat to dry said cement, winding said strip upon a core with the cemented underside of said strip engaging said core and the edges of adjacent convolutions engaging each other, and then further heating said strip to cure said strip and cause it to fuse into a homogeneous sheet upon said core.

6. The method of making brushes comprising forming individual bristle tufts by clamping together a multiplicity of plastic bristles with the corresponding ends of said bristles in substantially the same plane, subjecting said ends to sufficient heat to fuse them together into a thin beaded base integral with said bristles, inserting said tufts into spaced apertures in a narrow endless strip of uncured rubber with said beaded bases embedded in said strip with the bottoms thereof flush with the underside of said strip, winding said strip upon a core with the bases of said tufts engaging said core and the edges of adjacent convolutions of said strip engaging each other, and then applying sufficient heat thereto to cure said strip into a hard homogeneous sheet upon said core.

'7. The method of making brushes comprising forming individual bristle tufts by clamping together a multiplicity of plastic bristles with the corresponding ends of said bristles in substantially the same plane, subjecting said end to suflicient heat to fuse them together into a thin beaded base integral with said bristles, applying cement to the lower ends of said tufts, inserting the cemented ends of said tufts into spaced apertures in a narrow endless strip of uncured rubber with said beaded bases embedded in said strip with the bottoms thereof flush with the underside of said strip, winding said strip upon a core with the bases of said tufts engaging said core and the edges of adjacent convolutions of said strip engaging each other, and then applying sufficient heat thereto to cure said strip into a hard homogeneous sheet upon said core.

8. The method of making brushes comprising 14 forming individual bristle tufts by clamping together a multiplicity of plastic bristles with the corresponding ends of said bristles in substantially the same plane, subjecting said ends to sufficient heat to fuse them together into a thin beaded base integral with said bristles, inserting said tufts into spaced apertures in a narrow endless strip of uncured rubber with said beaded bases embedded in said strip with the bottoms thereof flush with the underside of said strip, applying cement to the underside of saidstrip and to the bases of said tufts, winding said strip upon a core with the cemented bases of said tufts and the cemented underside of said strip engaging said core and the edges of adjacent convolutions of said strip engaging each other, and then applying sufflcient heat thereto to cure said strip into a hard homogeneous sheet upon said core.

9. The method of making brushes comprising forming individual bristle tufts by clamping together a multiplicity of plastic bristles with the corresponding ends of said bristles in substantially the same plane, subjecting said ends to suificient heat to fuse them together into a thin beaded base integral with said bristles, applying cement to the lower ends of said tufts, inserting the cemented ends of said tufts into alined apertures in a narrow endless strip of uncured rubber with said beaded bases embedded in said strip with the bottoms thereof flush with the, underside of said strip, applying cement to the underside of said strip and to the bases of said tufts, winding said strip upon a core with the cemented bases of said tufts and the cemented underside of said strip engaging said core and the edges of adjacent convolutions of said strip engaging each other, and then applying sufficient heat thereto to cure said strip into a hard homogeneous sheet upon said core.

10. The method of making brushes comprising forming individual bristle tufts by clamping together a multiplicity of plastic bristles with the corresponding ends of said bristles in substantially the same plane, subjecting said ends to suflicient heat to fuse them together into a thin beaded base integral with said bristles, applying cement to the lower ends of said tufts, inserting the cemented ends of said tufts into alined apertures in a narrow endless strip of uncured rubber with said beaded bases embedded in said strip with the bottoms thereof flush with the underside of said strip, applying cement to the underside of said strip and to the bases of said tufts, subjecting said strip to only sufficient heat to dry said cement, winding said strip upon a core with the bases of said tufts engaging said core and the edges of adjacent convolutions of said strip engaging each other, and then further heating said strip to cure said strip into a hard homogeneous sheet upon said core.

JOHN A. STARR.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 866,784 Glorieux Sept. 24, 1907 1,280,944 Barry Oct. 8, 1918 2,061,129 Angell Nov. 17, 1936 2,190,206 Churchill Feb. 13, 1940 2,438,156 Dodge i Mar. 23, 1948 

